Beckman et



May 24, 1960 G. BECKMAN ETAL 24,823

METALLIC SURFACED INSULATING STRUCTURAL MATERIALS FOR smmc AND ROOFINGOriginal Filed April 15, 1954 2 Sheets-Sheet 1 MATERIALS FOR SIDING ANDROOFING Original Filed April 15, 1954 2 Sheets-Sheet 2 I /6' I k 2/." 1

I," u A5 n 23 United States Patent METALLIC SURFACED INSULATING STRUC-TURAL MATERIALS FOR SIDING AND ROOFING George Beckman, Lowell, Ind., andJohn Robert, Chicago, Ill., assignors to Globe Siding Products Company,Whiting, Ind., a corporation of Delaware Original No. 2,856,647, datedOct. 21, 1958, Ser. No. 426,092, Apr. 15, 1954. Application for reissueMar. 17, 1959, Ser. No. 859,826

2 Claims. (CI. 20- 5) Matter enclosed in heavy brackets [II appears inthe original patent but forms no part of this reissue specification;matter printed in italics indicates the additions made by reissue.

This invention relates to composite sheets or rolls of metallicreflective and insulating materials having a high resistance toconduction so that their combination will enhance the qualities of theindividual materials and render them more suitable for exterior buildingpurposes during all seasons of the year, although certain featuresthereof may be used with equal advantage for other purposes.

It contemplates more especially an improved composite structuralmaterial comprising highly reflective metallic materials such as but notlimited to light-gauge aluminum of foil gauge of .006" or less which iscorrugated, grained or textured for strength and appearance for improvedapplication to thermally non-conductive material so that the productsresulting from their association can be used with increased efficiencyand advantage for structural and/or decorative purposes.

It is generally known that thin sheets of bright metallic materials suchas aluminum have a high thermally reflective characteristic, but suchmaterials do not resist conduction or transmission of heat or cold andare readily deformed by impact therewith. The combination of thinmetallic sheets such as aluminum that is preferably corrugated forstrength and appearance with a sheet material that has insulatingproperties and resists conduction as well as transmission of heat orcold, constitutes a desirable combination for roof sheeting, buildingsiding and underflooring Where there are no basements and moistureladencold air has ready access.

Furthermore, metallic sheeting such as aluminum even in a thin gauge offoil thickness of .006" or less possesses the desired tensile strengthand the thermally reflective properties which combine with theinsulating properties of asphaltum sheet materials, such as saturatedfelt or saturated insulating board, plywood, and pressboard, to giveprotective body thereto and resist the thermal transmission andconduction of heat and cold. The lamination of such sheets of materialin the continuity of production operations is comparatively difficultbecause of the substantial differences in their tensile strength,coeflicient of expansion and contraction and their respectiveresistances to bending and deformation; however, this problem has beensolved by special flanged connection therebetween to compensatetherefor.

Resort to an adhesive alone to retain these different sheets inlaminated association is not considered entirely satisfactory, sothat'the problem has been solved by flanging the metallic sheet aroundthe edges of saturated felt or building siding so that a permanentlytacky adhesive can be utilized to preclude the creasing or rupture ofthe highly flexible sheeting materials. Then, too, it is preferablethough not essential, to corrugate, grain or texture the metallic sheetsto increase their rigidity, compensate for expansion and contraction andto provide an Re. 24,828 Reissued May 24, 1960 impressive surfacedesign. To accomplish the lamination of such sheeting material in thecontinuity of production operations has required special processing andmechanical expediency in view of the delicate nature of these materialsfrom the standpoint of their differences in tensile strength,coeflicient of expansion and contraction and their delicate characterfrom the standpoint of possessing little or no resistance to deformationwhile the sheets are under processing for association with each other.

It should be observed that uncorrugated or plain aluminum hollow sidinghas heretofore been proposed and used; however, such siding materialshave no substantial insulating value, rattle while being subjected towinds and storms, deform on impact or pressure, are not airproof orwind-proof, and cannot be striated because their substantial thicknessof .024" or more will crack through upon being corrugated, and suchsiding materials are not sufliciently stifi for practical purposes. Itis also necessary to use accessories for locking shingles or siding ofthis type or structure in place, and it would be difficult if notimpossible to use metallic sheets of foil thickness which is .004" orless and a maximum of .006 or even somewhat thicker gauge which can bestriated for strength and appearance and adapt themselves forutilization and association with shiplapped impregnated insulating boardor plain laminated impregnated sheets of heavy felt or laminatedsaturated sheets of roofing felt.

These materials besides being in flanged association may be caused toadhere over the entire contacting area for further protection by resortto an extra coating such as bitumen, resin, asphalt, pitches, or otheradhesives which preferably have a permanently tacky consistency. Withthe teachings of the present invention, the metallic foil sheet such asaluminum of substantially .005" thickness (plus or minus) can bestriated for strength and eflfectively flanged to a shiplap insulatingboard which is covered therewith on three sides and has a plain coverededge on the fourth side to compensate for expansion and contraction.Then, too, such thin metallic foil materials can be flanged over thebutt-ends of insulating materials such as laminated sheets of asphaltumimpregnated felt, plywood, or pressboard, and these materials shaped toserve as effective siding and/or roofing materials.

One object of the present invention is to provide an improved compositesheet of metallic and insulating material for building structuralpurposes.

Another object is to provide an improved corrugated metallic sheet ofthin material having a highly reflective surface for association with athermally non-conductive material such as asphaltum impregnated sheetsor insulating board that will resist heat penetration in summer and coldin winter.

Still another object is to provide improved shiplap aluminum corrugatedcomposite materials that are in flanged association to retain anasphaltum insulating material therewith for use as an external buildingroofing or siding sheet and/or both or for interior walls and decorativeelfects depending upon their structural details which control theirapplication.

A further object is to provide a plain or striated painted or upaintedmetallic material in flanged association with an insulating board toprovide a composite building material for application to roofs, siding,or other portions of building structures where appearance, insulatingqualities, and moisture barriers are important considerations.

A still further object is to provide a composite sheet of plain orstriated aluminum preferably of foil thickness in flanged associationwith asphaltum impregnated insulating material to serve as a thermal andmoisture barrier in conjunction with the reflective metallic surfacingmaterial which also is corrosion resistant.

Still a further object is to provide an improved composite buildingmaterial consisting of a plain or striated metallic foil in improvedflanged association with an insulating board or laminated sheets toprovide a more efiicient exterior building material having improvedappearance qualities, and is more durable and weather resistin-g.

Other objects and advantages will appear from the following descriptionof an illustrated embodiment of the present invention.

In the drawings:

Figure l is a plan view of a shiplapped composite panel embodyingfeatures of the present invention.

Figure 2 is a plan view of the underside or opposite surface of thepanel shown in Figure 1.

Figure 3 is an edge view in elevation of the panel shown in Figures '1and 2.

Figure 4 is an enlarged fragmentary plan view of several panels of thetype illustrated in Figures 1 to 3 inc1usive in complementalassociation.

Figure 5 is a fragmentary sectional view in elevation takensubstantially along line V--V of Figure 4.

Figure 6 is a plan view of a modified butt-end composite sheetconsisting of striated metallic foil in flanged association with two ormore laminated sheets of asphaltum impregnated felt.

Figure 7 is a plan view of the underside or opposite surface of thepanel shown in Figure 6.

Figure 8 is an enlarged fragmentary plan view of several panels of thetype illustrated in Figures 6 and 7 in complemental association.

Figure 9 is a fragmentary enlarged plan view of the striated surface ofthe composite sheet shown in Figures 6 to 8 inclusive and illustratingthe upraised portions of the striated surfaces opposite to those shownin Figures 1 to 5 inclusive to give a different visional striatedeffect.

Figure 10 is an enlarged fragmentary sectional view taken substantiallyalong line X--X of Figure 9.

The structure selected for illustration is not intended to serve as alimitationupon the scope or teachings of the invention, but is merelyillustrative thereof. There may be considerable variations andadaptations of all or part of the teachings depending upon the dictatesof commercial practice. The present embodiment comprises a substantiallyrectangular sheet of insulating board 10 which is a standard product onthe market and is preferably though not essentially impregnated withasphaltum compounds to render such resistant to moisture and to increasethe rigidity thereof. The substantially rectangular sheet 10 prior toimpregnation is preferably though not essentially shiplapped to provide,in this instance, three edges of shiplap construction 11-12-43.

In the present embodiment the three contiguous edges 11-42-13 face inone direction, namely toward the back surface 14 and the remainingshiplapped end 15 faces the front to serve as a complement of theopposite shiplapped edge 12 on the adjacent insulating board 10. Itshould be noted that the shiplapped end 15 faces the front panel of theboard 10 opposite to the back surface 14 thereof so that the insulatingboard 10 can be reversed in position with each lateral tier or course toprovide interfitting complemental association with the oppositelydisposed shiplapped end 12. This will provide the contiguous joinder oflateral courses with interfitting joints that are resistant to climaticconditions. The impregnation of the shiplapped insulating board 10renders such resistant to moisture and thermally non-conductive of heatand cold, but such structural materials are not eflectively resistant tosurface defects by abrasion, impact, and climatic erosion.

Furthermore, such materials do not reflect the suns rays which areresponsible for a substantial part of the thermal radiation during thehigh heat of the summer months and to overcome this as well as toprovide a more substantial exterior sur -face with improved appearancecharacteristics, a thin metallic material 16 in physical associationwith the insulating board 10 results in a composite building materialhaving improved thermal characteristics, wearing qualities, and anattractive appearance. The metallic surfacing materials 16 for economicand production considerations should be preferably of foil thicknesswhich is anywhere up to .006" (plus or minus) and this material ispreferably though not essentially of aluminum that has high reflectiveproperties.

Foil sheet material of this thinness can be striated or corrugated toincrease the rigidity thereof and to provide an attractive surfacedesign as well as compensate for expansiori and contraction in thecomposite structural material. To this end, the thin metallic sheetmaterial 16 within the thickness prescribed by way of illustrationrather than limitation, consists of a sheet 16 that is sufficientlywider and longer than the substantially rectangular insulating board 10of comparatively much greater thickness including its shiplapped edges11-12-13-15 to provide an underlap 17-18-19 that are folded around andover the shiplaps 1112-13 for flanged association therewith. Thealuminum fold-over flanges cover the underside of the shiplap 17-18-19up to the peripheral shoulder 2021--22 defined by the shiplapped edges1112-13 with the full thickness of the board 10. A suitable normallytacky adhesive 24 known in the building industryv may be interposedbetween the adjacent surface of the metallic sheeting 16 and the board10, and should commercial practice so dictate, this may also be appliedto the flanged underlaps 171819 and edge lap 23.

The shiplapped end 15 which faces the front panel of the board 10(Figures 1 and 3) has the aluminum overlap extending down along theperipheral shoulder 23 formed by the shiplap 15 with the full thicknessof the board 10, but at this end the end overlap 23 extends downwardlyto the shiplapped edge 15 and not thereover, thereby enabling the foilsheet material 16 and the insulating board 10 to compensate for thevariations in expansion and contraction since there is a substantialdifference in the coefficient of expansion and contraction between thesesubstantially different materials. It should be observed that thispermits the shiplap end 15 to be fully exposed and uncovered in thedirection of the front panel 10, and it will serve as a complement ofthe shiplap 12 on the opposite end of the next adjacent panel 10 ofaluminum covered insulating board so that a double thickness of aluminumwill not be interposed between laterally adjacent sheets of insulatingboard 10;

The aluminum covered insulating board 10 when shiplapped as illustratedand described herein, is used for lap siding of superposed courses, andthese are held in position by nails which are applied through thecomposite sheets 1016 of aluminum covered insulating board 10 in thearea of the overlap of the next superimposed course for completeconcealment and protection against the weather. The insulating board 10is preferably first impregnated with a substantial film of asphaltum orother asphaltic compounds prior to the application of the aluminum sheet16 thereof in the manner described supra. To insure a better associationbetween the aluminum sheet 16 and the insulating board 10, it may alsobe desirable to provide a normally sticky adhesive 24 to the surfacesthat come in contact with the aluminum 16, and this adhesive will tendto improve the thermal [qualities] of the composite sheet 10-'16 as wellas eifect a more pergnanent joinder between the aluminum sheet 16therewit It is also desirable and preferable to corrugate or striate thealuminum sheet 16 prior to its application to the insulating board 10,and to this end a series of parallel corrugations preferably though notessentially vertical, although such could be horizontally or diagonallydisposed, are rolled or otherwise provided therein to present valleys 25and nodes 26. The valleys 25 and nodes 26 are striated with any desiredspacing relative to each other depending upon the considerations of theappearance desired thereof and the dictates of commercial practice as tothe reinforcing qualities to be imparted thereto. As shown, the nodes 26are, in this instance, non-uniformly spaced in a particular patternrelative to the valleys 25 therebetween, and the latter may comprise theplane of the sheet 16 for contact with the surface of the insulatingboard 10. The'plane of the sheet 16 comprising the valleys 25 of thestriations 2526 will be in contact with the insulating board 10. Thestriations 25-26 will create a particular visual impression, but byreversing the sheet 16 so that the corrugations or striations 26 will bein contact with the surface of the insulating board 10, a differentvisual effect and design will be produced owing to the variations inspread or spacing as between the valleys and nodes 25--26.

This may prove advantageous, and the selection of the pattern as well asthe closeness of the nodes 26 depends upon the dictates of commercialpractice to provide a composite sheet that is durable, solid, and willwithstand variations in wind pressures and impact without any noisefactor. It should also be noted that the nodes 26 of the corrugations2526 provide an air space which will allow any excess adhesive 24 tooccupy the space provided therebeneath should elevated temperaturescause an increase in volume thereof. Then, too, it may be desirabledepending upon the experience and dictates of 5 commercial practice toprovide an excessive thickness of adhesive film 24 so that the spacebeneath the nodes 26 of the corrugations 25-26 will be filled therewithto provide a solid backing therefor and to preclude deformation byimpact or external load thereon.

With this arrangement and construction, it will be apparent thatapplicants have provided improved insulated siding or shingle compositematerials which will be highly reflective to the suns rays and willresist the radiation and transmission of heat or cold therethrough. Thealuminum covering panel 16 may be painted with bright colors of anydesired choice should commercial practice so dictate, since brightcolors are known to be almost as reflective to the sun's rays as naturalaluminum. The corrugations in the metal foil panels 16 impart a pleasingappearance and design to the surface of the siding and shingles,increase the rigidity thereof, minimize deformation and totallyeliminate the noise factor due to winds and other external influences.The provision of a plain fold-over edge 23 on one lateral end of theshiplapped board 10 together with the striations or corrugations 25-26compensate for variations in expansion and contraction between the twocomposite materials 10--16, and a much more durable composite structuralmaterial results by resort to the teachings of the present invention.

In the modified embodiment illustrated in Figures 6 to 10 inclusive, theshiplapped construction of the board 10 is dispensed with, and either abuttor square-edged insulating board 10' is provided. In the specificembodiment illustrated herein, multiple layers of dry or impregnatedheavy felt Illa-10b are utilized (Figure 10). With the use of laminatedasphaltic impregnated felt ltla-ltlb, in this instance two layers, arepreferably though not essentially of SO-gauge, or dry felt may beadhered together with asphaltic, plastic, or petroleum resin or pitcheswhich are normally tacky to provide an adhering film 10c therebetween.The film laminations 10a10b are preferably flexible for use either assiding or roofing, and are covered with panels 16 of aluminum foil whichis first striated or corrugated to provide valleys 25 and nodes 26' ofthe same or opposite spacing as that shown in the previous embodiment.

The sheet '16 is preferably larger than the rectangular expanse of thelaminated insulating base 10' so that the edges 20'21'--22'23 thereofcan be folded over and 6 under the insulating board 10 to provideflanged underlaps which are mitered at their corners to completelyenclose the top surface thereof and the edges 11'12' 13'15' to exposethe back surface 14' thereof except in the region of the flangedunderlaps 2021'22' -23'. The metallic foil 16' is preferably in adheringcontact with the base consisting, in this instance, of the laminatedsheets of felt 10a---10b by resort to a film of petroleum pitch, resin,or plastic normally tacky adhesives 24 which are well known in theinsulating siding and roofing industry. Should commercial practice sodictate, the flanged underlaps 20'-21'22--23 may also be in adheringcontact by resort to the tacky adhesive film 24; however, this mayinvolve some production problems and with this arrangement, the buttorsquare-edged composite sheets 10'16' are applied as lap siding withalternate meeting joints in brick formation as illustrated in Figure 8.With this type of siding, a vertical joint strip known in the trade as aBakerstrip is nailed to the building structure beneath the joint toeliminate rain and moisture leakage.

These painted or unpainted composite sheets 10 -16 are attached withnails that are concealed by the lap in the superimposed course orattached by resort to clips in the same manner as locked-down roofingand siding. The improved feature is the provision of ornamented metallicsurfaces which have striations or corrugations therein to compensate forthe variations in expansion and comtraction between the two materialsand to rigidify normally flexible and comparatively thin laminations ofdry or saturated felt Illa-10b with or without adhering films ofadhesives such as petroleum pitch, resins, and plastics known in theindustry and utilized for other purposes. The highly advantageousproperties of metallic foil with those of insulating materials, havebeen combined into composite structural materials that have enhancedwearing properties, improved thermal characteristics, better and morepermanent exposed surfaces, and can be produced with necessary limits ofexpense to meet the demands for such an improved composite buildingstructural material.

While we have illustrated and described a preferred embodiment of thisinvention, it must be understood that the invention is capable ofconsiderable variation and modification without departing from thespirit of the invention. We, therefore, do not wish to be limited to theprecise details of construction set forth, but desire to avail ourselvesof such variations and modifications as come within the scope of theappended claims.

We claim:

'1. A building board, comprising an elongated sub stantially rectangularrelatively thick [fibrous] foundation board, said foundation boardhaving four edges with generally half-thickness half-lap edge portionstherealong, three of said four half-thickness edge portions being at thefront of said foundation board, the fourth of said half-thickness edgeportions being at the rear of said foundation board and along theshorter dimension thereof, said fourth half-thickness edge portiondefining an inset laterally facing shoulder extending along the front ofsaid foundation board at the base of said fourth halfthickness edgeportion, and a continuous relatively thin metal sheet covering the frontof said [fibrous] foundation board with adhesive material therebetween,said metal sheet having a plurality of corrugations formed therein andextending transversely to the longer dimension of said foundation board,said metal sheet having three underturned edge flanges extendingtherefrom around and under said three half-thickness edge portions atthe front of said foundation board, said metal sheet having a fourthedge flange turned downwardly and covering said shoulder, said fourthedge flange terminating substantially at the base of said fourthhalf-thickness edge portion.

2. A building board, comprising an elongated substantially rectangularrelatively thick [fibrous] foundation board, said foundation boardhaving four edges with generally half-thickness half-lap edge portionsthereaong, three of said four half-thickness edge portions being at thefront of said foundation board, the fourth of said half-thickness edgeportions being at the rear of said foundation board, said fourthhalf-thickness edge portion defining an inset laterally facing shoulderextending along the front of said foundation board at the base of saidfourth half-thickness edge portion, and a continuous relatively thinmetal sheet covering the front of said [fibrous] foundation board, saidmetal sheet having three underturned edge flanges extending therefromaround and under said three half-thickness edge portions at the front ofsaid foundation board, said metal sheet having a fourth edge flangeturned downwardly and covering said shoulder, said fourth edge flangeterminating substantially at the base of said fourth half-thickness edgeportion.

References Cited in the file of this patent or the original patentUNITED STATES PATENTS

